Cowboy-hat shaped washer for a metal roof deck and method for fastening a roof deck

ABSTRACT

Disclosed herein is a washer having a substantially planar annular area defining an opening for through passage of a fastener and a non-planar area radially outwardly disposed of the planar annular area. A method for fastening a roof deck comprising inserting a fastener through a washer having a substantially planar annular area and a non-planar area radially outwardly disposed of the planar annular area and driving the fastener through the roof deck or through an opening therein. A corrugated metal roof deck system comprising a subjacent support and a corrugated metal roof supported by the support. A waster having a substantially planar annular area defining an opening for through passage of a fastener and a second non-planar area radially outwardly disposed of said planar annular area with a fastener extending through said washer through said deck and into said subjacent support.

BACKGROUND

Metal roof decking, usually but not exclusively corrugated, is employedin many commercial buildings and storage buildings as well as someresidential buildings. Most metal decks are paddle welded to theunderlying structure. Welding is inconsistent and weak. It is alsosubject to rust and corrosion because it bums the protective coating offboth sides of the steel decking at its interface. Recently some metalroof decking material is affixed by fasteners such as screws. To spreadto a larger surface area any load placed on the roof deck by the screwhead during wind uplift or similar events, a flat washer has commonlybeen placed under the screw head. While this does indeed spread some ofthe load of the screw, it also causes a point stress especially incorrugated decking material. This point stress is created where the flatwasher intersects the curved corrugation.

Roof failures have occurred due to penetration of the roof deck at thesepoint stress points during wind uplift and consequent tearing of theroof decking from the penetration point around the fasteners. This ofcourse leads to an easy undesired removal of the roof assembly aftersufficient fastening points have been compromised causing extreme deckdeflection in high winds.

SUMMARY

Disclosed herein is a unique and novel washer having parallel edges bentup like the edges of a cowboy hat brim. A washer having a substantiallyflat annular area defining an opening for through passage of a fastenerand a bent radially outwardly disposed of the planar annular area.

A method for fastening a roof deck comprising inserting a fastenerthrough a washer having a substantially flat area and a bent arearadially outwardly disposed of the flat area such that the washerresembles a cowboy hat and driving the fastener through the cowboy hatwasher, through an opening therein the roof deck and into the underlyingstructural support beam.

A corrugated metal roof deck system comprising a subjacent support and acorrugated metal roof supported by the support. A washer having asubstantially flat area defining an opening for through passage of afastener and a bent area radially outwardly disposed of said flat areawith a fastener extending through the washer, through the deck and intothe subjacent support.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings wherein like elements are numbered alikein the several Figures:

FIG. 1 is a perspective view of a washer as disclosed herein;

FIG. 2 is a cross-sectional view;

FIG. 3 is a perspective view of a washer of FIG. 1 in a trough of ametal corrugated deck for a roof; and

FIG. 4 is a cross-sectional view similar to FIG. 2 with a fastenerextended therethrough.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2 simultaneously, washer 10 comprises anexpanse of material 12 of 1¼″ (in one embodiment) having a first section14 and at least one second section 16. Material 12 defines an opening 18for through passage of a separate structure. In one embodiment theseparate structure is a fastener such as a nail or screw. Opening 18 maybe dimensioned to closely approximate a nominal diameter of the shank 20of the fastener 22 intended to pass therethrough such that a head 24 ofsuch fastener (FIG. 4) cannot pass through. In one embodiment, the firstsection 14 includes a substantially flat area 18 of washer 10 which issized sufficiently to be contacted in a substantially flush manner byundersurface 26 of head 24 of fastener 22. The second section 16 ofwhich includes bent areas 30. The bent areas 30 of section 16 are in oneembodiment bent in a parallel manner to one another and cause the washer10 to resemble a cowboy hat brim. The shape advantageously closelyapproximates a shape of a trough 32 (FIG. 3) in a corrugated metal deck34 (such as a type “B” corrugated metal deck or other corrugatedmaterial). Because of the bent configuration of the washer, there are nosignificant stress points created by the washer on a corrugated roofdeck during a wind uplift condition. Without the stress points, thefastener/washer assembly is far less likely to pull through the roofdeck or have the roof deck rip through the washer. Accordingly, failureis deferred to much higher wind uplift pressures and fatigue cycling. Intesting of the device and method disclosed herein, the roof deck did notfail at maximum test criteria of 225 pounds per square foot and 280pounds per square foot at two respective testing facilities. It is to beunderstood that although the term “bent” suggests a metallic structureof washer 10 and even though a metallic structure is indeedcontemplated, other materials may be employed including plastics. In thecase of metals or plastics, the washer may either be bent as describedor may be molded as such.

The method for fastening a roof deck comprises producing a washer havingcharacteristics described hereinabove. This can be accomplished by suchmeans as stamping, rolling, hot forming, molding, casting, etc.

The formed washer is then deposited on a fastener of a type and shapecapable of passing through the opening in washer 10 as described above.In this condition the fastener and washer combination is driven throughthe deck with the fastener extending into a subjacent support.

A roof deck secured with a plurality of the fastener/washer combinationdescribed herein is capable of withstanding extraordinarily high winduplift forces without failure.

While preferred embodiments have been shown and described, modificationsand substitutions may be made thereto without departing from the spiritand scope of the invention. Accordingly, it is to be understood that thepresent invention has been described by way of illustrations and notlimitation.

1. A washer defining a first surface and a second surface, the first andsecond surfaces remaining equidistant from one another at all points ofthe washer, the washer being for a metal roof deck comprising: asubstantially flat area defining an a single opening for through passageof a fastener; and a bent area radially outwardly disposed of said flatarea configured to nest with a corrugation in the metal roof deck, theflat area and the bent area being of a single contiguous uninterruptedpiece of material absent holes other than the opening for throughpassage of the fastener.
 2. A washer for a metal roof deck as claimed inclaim 1 wherein said washer is rolled in the bent area.
 3. A washer fora metal roof deck as claimed in claim 1 wherein said bent area is rolledless than 90°.
 4. A washer for a metal roof deck as claimed in claim 1wherein said washer is metal.
 5. A washer for a metal roof deck asclaimed in claim 1 wherein said washer is plastic.
 6. A washer for ametal roof deck as claimed in claim 1 wherein said washer is bent on twolateral sides thereon.
 7. A washer for a metal roof deck as claimed inclaim 6 herein said bent areas are in parallel to each other.
 8. Awasher for a metal roof deck as claimed in claim 1 wherein said bentareas is are ¼″ wide.
 9. A method for fastening a corrugated metal roofdeck comprising: depositing a washer having an area radially outwardlydisposed; expanse of metal material having a circular outer periphery ifrendered flat with a first surface and a second surface remainingsubstantially the same distance from each other throughout the expanseof the washer; a single opening in the expanse of material of the washerdimensioned to closely receive the fastener therethrough; asubstantially flat area of the washer; a bent area radially outwardlydisposed of the flat area, the bent area disposing both the first andsecond surface of the washer out of plane with the flat area of thewasher, said bent area causing said washer to substantially nest with acorrugation of the corrugated metal roof deck; driving said fastenerthrough a corrugated metal roof deck into a structural joist; orientingsaid washer complementarily to said roof deck; and securing said washerand roof deck by tightening said fastener against the structuralunderlying joist.
 10. A roof assembly comprising: a subjacent support; acorrugated metal roof deck supported by the support; and a washer havingthe first surface and a second surface, the surfaces being consistentlyspaced from one another over the entirety of the washer, the washerhaving a substantially flat area defining an a single opening forthrough passage of a fastener and a bent area radially outwardlydisposed of the flat area; a fastener extending through said washer,through said deck and into said subjacent support.
 11. A roof assemblyas claimed in claim 10 wherein said washer is rolled in the bent area.12. A roof assembly as claimed in claim 10 wherein said washer is rolledparabolically.
 13. A roof assembly as claimed in claim 10 wherein saidwasher is metal.
 14. A roof assembly as claimed in claim 10 wherein saidwasher is plastic.
 15. A roof assembly as claimed in claim 10 whereinsaid washer is thicker than the deck metal.
 16. A roof assembly asclaimed in claim 10 wherein the washer conforms to the shape of thecorrugation resting on the sub-adjacent support.
 17. A metal washer thatconforms to the shape of a type B corrugated metal deck smaller lowflute.
 18. A washer for fastening corrugated metal decks to structuralsupports bent in the configuration of the metal deck, the washer beingthicker than the metal decking and being greater than ¾″ of an inch inoutside diameter.
 19. A washer for corrugated metal roof deck, thewasher comprising: an expanse of metal material having a circular outerperiphery if rendered flat with a first surface and a second surfaceremaining substantially the same distance from each other throughout theexpanse of the washer; a single opening in the expanse of material ofthe washer dimensioned to closely receive a fastener therethrough; asubstantially flat area of the washer; a bent area radially outwardlydisposed of the flat area, the bent area disposing both the first andsecond surface of the washer out of plane with the flat area of thewasher, the bent area causing the washer to substantially nest with acorrugation of the corrugated metal roof deck.